Inductive power transfer

ABSTRACT

One embodiment provides a non-contact power transmitter device including a sealed housing provided at least partially within a surface, and a transmitter coil within the sealed housing configured to inductively transfer power to a power receiver device. The power transmitter device also includes a transmitter control unit coupled to the transmitter coil, a transceiver configured to communicate with the power receiver device, and an electronic processor coupled to the transmitter control unit and the transceiver. The electronic processor is configured to establish, using the transceiver, communication with the power receiver device, and negotiate power transfer requirements between the power transmitter device and the power receiver device. The electronic processor is also configured to control the transmitter control unit to transfer power to the power receiver device.

RELATED APPLICATIONS

This application is continuation of U.S. patent application Ser. No.16/811,667 filed on Mar. 6, 2020, now U.S. Pat. No. 11,177,694, whichclaims priority to U.S. Provisional Patent Application No. 62/815,128,filed Mar. 7, 2019, the entire contents of which are hereby incorporatedby reference.

FIELD

The present disclosure relates generally to inductive power transferbetween electrical devices.

SUMMARY

Users of electrical devices often prefer such devices without wires toprevent tripping and damage to electrical devices due to inadvertentpulling of power cords during operation or when the electrical devicesare moved. Additionally, elimination of wires also simplifies the designof electrical devices. Electrical devices without wires are typicallypowered by batteries. Batteries, however, have limited run-time andcapacity. Mid-power range devices such as office and home appliancesconsume between approximately 0.1 to 3.2 kilowatts of power. To powerthese devices using batteries requires very large batteries affectingthe portability of the devices. Additionally, batteries must typicallybe charged regularly, which requires wired chargers and decommissioningof the device while the batteries are being charged.

Additionally, in harsh or hazardous environments, sealed/waterproofelectrical devices are needed. In these environments, power cords andexposed power outlets may pose an additional hazard to the environment.

Accordingly, there is a need for wireless mid-range power transfersystems that improve the portability and user accessibility ofelectrical devices. Additionally, there is a need for wireless mid-rangepower transfer systems that are sealed and are waterproof.

One embodiment provides a non-contact power transmitter device includinga sealed housing provided at least partially within a surface, and atransmitter coil within the sealed housing configured to inductivelytransfer power to a power receiver device. The power transmitter devicealso includes a transmitter control unit coupled to the transmittercoil, a transceiver configured to communicate with the power receiverdevice, and an electronic processor coupled to the transmitter controlunit and the transceiver. The electronic processor is configured toestablish, using the transceiver, communication with the power receiverdevice, and negotiate power transfer requirements between the powertransmitter device and the power receiver device. The electronicprocessor is also configured to control the transmitter coil unit totransfer power to the power receiver device.

Another embodiment provides a non-contact power transfer systemincluding a power transmitter device and a power receiver deviceconfigured to be coupled in a power transfer relationship with the powertransmitter device. The power transmitter device includes a sealedhousing provided at least partially within a surface, and a transmittercoil within the sealed housing. The power transmitter device alsoincludes a transmitter control unit coupled to the transmitter coil, atransmitter transceiver, and a transmitter electronic processor coupledto the transmitter control unit and the transceiver. The power receiverdevice includes a second sealed housing provided at least partiallywithin an electrical appliance, and a receiver coil within the sealedhousing. The transmitter coil is configured to inductively transferpower to the receiver coil. The power receiver device also includes apower conversion unit coupled to the receiver coil, a receivertransceiver, and a receiver electronic processor coupled to the powerconversion unit and the receiver transceiver.

Another embodiment provides a method for bi-directional non-contactpower transfer including establishing communication between a firstelectrical device and a second electrical device of a bi-directionalpower transfer system, and determining one of the first electricaldevice and the second electrical device as a power transmitter and otherof the first electrical device and the second electrical device as apower receiver. The method also includes converting input power of thepower transmitter to an AC power, and providing the AC power to atransmitter coil of the power transmitter. The method further includesgenerating, using the transmitter coil, an oscillating magnetic field,and generating an alternating current in a receiver coil of the powerreceiver based on the oscillating magnetic field. The method alsoincludes converting the alternating current to a direct current, andproviding the direct current to a load of the power receiver.

Another embodiment provides a method for non-contact power transferincluding establishing communication between a power transmitter deviceand a power receiver device, and negotiating power transfer requirementsbetween the power transmitter device and the power receiver device. Themethod also includes providing a first alternating current to atransmitter coil of the power transmitter device, and generating, usingthe transmitter coil, an oscillating magnetic field. The method furtherincludes generating a second alternating current in a receiver coil ofthe power receiver device based on the oscillating magnetic field, andconverting the second alternating current to output power. The methodalso includes providing the output power to a load of the power receiverdevice.

Another embodiment provides a non-contact power transfer systemincluding a power transmitter device and a power receiver deviceconfigured to be coupled in a power transfer relationship with the powertransmitter device. The power transmitter device includes a flat baseportion, and a transmitter coil provided in the flat base portion. Thepower transmitter device also includes a raised ledge portion around theflat based portion having an opening on an inner side of the raisedledge portion. The power receiver device includes a flat portion, and araised portion configured to be received in the opening formed by theraised ledge portion of the power transmitter device. The power receiverdevice includes a receiver coil provided in the raised portion.

In some constructions, a first magnet is provided in the flat baseportion in the center of the transmitter coil, and a second magnet isprovided in the raised portion in the center of the receiver coil. Whenthe raised portion is received in the opening formed by the raised ledgeportion, the first magnet is coupled to the second magnet due to themagnetic force between the first magnet and the second magnet.

Another embodiment provides a method for non-contact power transferincluding establishing, using a transceiver of a power transmitterdevice, communication with a plurality of power receiver devices, anddetermining, using an electronic processor of the power transmitterdevice, priority and power requirements of the plurality of powerreceiver devices. The method also includes dividing, using theelectronic processor, the power between a plurality of transmitter coilsof the power transmitter device based on the priority and powerrequirements of the plurality of power receiver devices coupled to theplurality of power transmitter coils.

Another embodiment provides a non-contact power transmitter deviceincluding a plurality of transmitter coils configured to inductivelytransfer power to a plurality of power receiver devices, and atransmitter control unit coupled to the plurality of transmitter coils.The power transmitter device also includes a transceiver configured tocommunicate with the plurality of power receiver devices, and anelectronic processor coupled to the transmitter control unit and thetransceiver. The electronic processor is configured to establish, usingthe transceiver, communication with the plurality of power receiverdevices, and determine priority and power requirements of the pluralityof power receiver devices based on the communication with the pluralityof power receiver devices. The electronic processor is also configuredto control the transmitter coil unit to divide the power between theplurality of transmitter coils based on the priority and powerrequirements.

Another embodiment provides a method for non-contact power transferincluding establishing communication between a power transmitter deviceand a power receiver device, and negotiating power transfer requirementsbetween the power transmitter device and the power receiver device. Themethod also includes providing a first alternating current to atransmitter coil of the power transmitter device, and generating, usingthe transmitter coil, an oscillating magnetic field. The method furtherincludes generating a second alternating current in a receiver coil ofthe power receiver device based on the oscillating magnetic field, andconverting the second alternating current to output power. The methodalso includes providing the output power to a load of the power receiverdevice. The second alternating current is a single phase alternatingcurrent and converting the second alternating current to the outputpower includes converting the single-phase alternating current tomulti-phase alternating current.

Another embodiment provides a method for non-contact power transferincluding establishing communication between a power transmitter deviceand a power receiver device, and negotiating power transfer requirementsbetween the power transmitter device and the power receiver device. Themethod also includes providing a first alternating current to atransmitter coil of the power transmitter device. The first alternatingcurrent is a multi-phase alternating current. The method furtherincludes generating, using the transmitter coil, an oscillating magneticfield, and generating a second alternating current in a receiver coil ofthe power receiver device based on the oscillating magnetic field. Themethod also includes converting the second alternating current to outputpower, and providing the output power to a load of the power receiverdevice.

Another embodiment provides a method for non-contact power transferincluding establishing communication between a power transmitter deviceand a plurality of power receiver devices, and determining, using anelectronic processor of the power transmitter device, priority and powerrequirements of the plurality of power receiver devices. The methodincludes dividing, using the electronic processor, a first AC inputbetween a plurality of transmitter coils of the power transmitter devicebased on the priority and power requirements of the plurality of powerreceiver devices coupled to the plurality of power transmitter coils.The first AC input is a multi-phase AC input.

Another embodiment provides a method for non-contact power transferincluding establishing communication between a power transmitter deviceand a power receiver device, and negotiating power transfer requirementsbetween the power transmitter device and the power receiver device. Themethod also includes providing a first alternating current to atransmitter coil of the power transmitter device, and generating, usingthe transmitter coil, an oscillating magnetic field. The transmittercoil is provided in a transmitter portion of the power transmitterdevice. The method also includes generating a second alternating currentin a receiver coil of the power receiver device based on the oscillatingmagnetic field. The receiver coil is in a receiver portion of the powerreceiver device. The method further includes converting the secondalternating current to output power, and providing the output power to aload of the power receiver device. The transmitter portion and thereceiver portion are aligned to axially align the transmitter coil andthe receiver coil without an air gap between the transmitter portion andthe receiver portion.

Another embodiment provides a non-contact power transfer systemincluding a power transmitter device and a power receiver deviceconfigured to be coupled in a power transfer relationship with the powertransmitter device. The power transmitter device includes a flat baseportion, and a transmitter coil provided in the flat base portion. Thepower receiver device includes a flat portion configured to be alignedwith the flat base portion of the power transmitter device, and areceiver coil provided in the flat portion. The flat base portion andthe flat portion are aligned to axially align the transmitter coil andthe receiver coil without an air gap between the flat base portion andthe flat portion.

In some constructions, a first magnet is provided in the flat baseportion in the center of the transmitter coil, and a second magnet isprovided in the flat portion in the center of the receiver coil. Whenthe flat portion is aligned with the flat base portion, the first magnetis coupled to the second magnet due to the magnetic force between thefirst magnet and the second magnet.

BRIEF DESCRIPTION OF THE DRAWINGS

Detailed discussion of embodiments directed to one of ordinary skill inthe art are set forth in the specification, which makes reference to theappended figures, in which:

FIG. 1 is a block diagram of a bi-directional non-contact power transfersystem in accordance with some embodiments;

FIG. 2 is a flowchart of a method of operating the bi-directionalnon-contact separable wiring power transfer system of FIG. 1 inaccordance with some embodiments;

FIG. 3 is a block diagram of a non-contact power transfer system inaccordance with some embodiments;

FIG. 4 is a flowchart of a method of operating the non-contact powertransfer system of FIG. 3 in accordance with some embodiments;

FIG. 5 is a block diagram of a multi-node non-contact power transfersystem in accordance with some embodiments;

FIG. 6 is a flowchart of a method of operating a power transmitterdevice of the multi-node non-contact power transfer system of FIG. 5 inaccordance with some embodiments;

FIGS. 7A-C illustrate an example implementation of the non-contact powertransfer system of FIG. 3 implemented in a separable wiring device inaccordance with some embodiments;

FIGS. 8A-C illustrate an example implementation of the non-contact powertransfer system of FIG. 3 implemented in a separable wiring device inaccordance with some embodiments;

FIG. 9 illustrates an example implementation of the non-contact powertransfer system of FIGS. 7C and 8C in accordance with some embodiments;

FIG. 10A illustrates an example implementation of the non-contact powertransfer system of FIG. 3 implemented in a separable wiring device inaccordance with some embodiments;

FIG. 10B illustrates an example implementation of the non-contact powertransfer system of FIG. 3 implemented in a separable wiring device inaccordance with some embodiments; and

FIG. 11 illustrates an example implementation of the non-contact powertransfer system of FIG. 3 in accordance with some embodiments.

DETAILED DESCRIPTION

Before any embodiments of the disclosure are explained in detail, it isto be understood that the disclosure is not limited in its applicationto the details of construction and the arrangement of components setforth in the following description or illustrated in the followingdrawings. The disclosure is capable of other embodiments and of beingpracticed or carried out in various ways.

FIG. 1 is a block diagram of one embodiment of a bi-directionalnon-contact separable wiring device power transfer system 100. In theexample illustrated, bi-directional non-contact separable wiring devicepower transfer system 100 is an inductive power transfer systemincluding a first electrical device 110 and a second electrical device115 in a power transfer relationship with each other. In bi-directionalnon-contact separable wiring device power transfer system 100 electricalpower may be transferred from the first electrical device 110 to thesecond electrical device 115 or from the second electrical device 115 tothe first electrical device 110. First electrical device 110 includes afirst electronic processor 120, a first memory 125, a first transceiver130, a first power conversion circuit 135, a first control unit 140, anda first coil 145. Similarly, the second electrical device 115 includes asecond electronic processor 150, a second memory 155, a secondtransceiver 160, a second power conversion circuit 165, a second controlunit 170, and a second coil 175. The first electrical device 110 and thesecond electrical device 115 may include more or fewer components thanthose illustrated in FIG. 1 and may perform additional functions tothose described herein.

One example of a separable wiring device system is an electrical devicepair that can be separated in contrast to, for example, a permanentlyconnected or wired system. For example, a separable wiring device systemis a system in which two devices are connected using a plug andreceptacle and are, therefore, separable as opposed to connecting thetwo devices using a wire to wire soldered or bolted connection. In thebelow embodiments, the separable wiring device system includes twowiring devices that can be separated and the devices may be used withany other compatible transmitter or receiver combinations.

In some embodiments, the first electronic processor 120 is implementedas a microprocessor with separate memory, such as the first memory 125.In other embodiments, the first electronic processor 120 may beimplemented as a microcontroller (with the first memory 125 on the samechip). In other embodiments, the first electronic processor 120 may beimplemented using multiple processors. In addition, the first electronicprocessor 120 may be implemented partially or entirely as, for example,a field-programmable gate array (FPGA), an application specificintegrated circuit (ASIC), and the like, and the first memory 125 maynot be needed or may be modified, accordingly. In the exampleillustrated, first memory 125 includes non-transitory, computer-readablememory that stores instructions that are received and executed by thefirst electronic processor 120 to carry out functionality of the firstelectrical device 110 described herein. First memory 125 may include,for example, a program storage area and a data storage area. The programstorage area and the data storage area may include combinations ofdifferent types of memory, such as read-only memory and random-accessmemory. The second electronic processor 150 and the second memory 155are implemented similar to the first electronic processor 120 and thefirst memory 125.

The first transceiver 130 and the second transceiver 160 allow forcommunication between the first electrical device 110 and the secondelectrical device 115. In some embodiments, the first transceiver 130and the second transceiver 160 include separate transmitter and receivercomponents. The first transceiver 130 and the second transceiver 160enable wireless communication between the first electrical device 110and the second electrical device 115. For example, the first transceiver130 and the second transceiver 160 may comprise Bluetooth® modules,near-field communication (NFC) modules, out-of-band communicationmodules and the like that allow for short range wireless communicationbetween the first electrical device 110 and the second electrical device115. One skilled in the art would understand that other wirelesscommunication protocols could also be used consistent with the presentdisclosure.

The functionality of the first power conversion circuit 135, the firstcontrol unit 140, the first coil 145, the second power conversioncircuit 165, the second control unit 170, the second coil 175 will nowbe explained with respect to an example where the first electricaldevice 110 is configured as the power transmitter and the secondelectrical device 115 is configured as the power receiver. In thisexample, the first power conversion circuit 135 converts power receivedfrom a power input 180 into an alternating current (AC) power. Forexample, the first power conversion circuit 135 may include anoscillator controlled switching component to convert a direct current(DC) power input to an AC power output. In some embodiments, when theinput power is an AC power input, the first power conversion circuit 135may not be required or may be modified, accordingly, to convert the ACpower input to another form, such as AC power having a differentfrequency, phase, and/or magnitude than the AC input power.

The first control unit 140 is controlled by the first electronicprocessor 120 to provide the alternating current to the first coil 145.The alternating current through the first coil 145 creates anoscillating magnetic field around the first coil 145. The oscillatingmagnetic field induces an alternating electromotive force that createsan alternating current in the second coil 175. The second electronicprocessor 150 controls the second control unit 170 to provide thealternating current from the second coil 175 to the second powerconversion circuit 165. In one example, the second power conversioncircuit 165 converts the AC power received from the second coil 175 intoa DC power at a power output 185. For example, the second powerconversion circuit 165 may include a rectifier to convert the AC powerfrom the second coil 175 to a DC power output to a load. In someembodiments, when the load requires an AC power, the second powerconversion circuit 165 may not be required or may be modifiedaccordingly.

FIG. 2 is a flowchart illustrating one exemplary method 200 foroperating the bi-directional non-contact separable wiring device powertransfer system 100. It should be understood that the order of the stepsillustrated in method 200 could vary. Additional steps may also be addedto the control sequence and not all of the steps may be required. Asillustrated in FIG. 2 , method 200 includes establishing communicationbetween the first electrical device 110 and the second electrical device115 (at block 210). For example, a Bluetooth® connection, a Zigbee®connection, or some other suitable wireless communications method, maybe established between the first electrical device 110 and the secondelectrical device 115 to facilitate communication between the firstelectronic processor 120 and the second electronic processor 150. Thewireless communication between the first electrical device 110 and thesecond electrical device 115 using Bluetooth®, or other such wirelesscommunication, is referred to herein as “out-of-band communication.” Insome embodiments, an “in-band communication” based on modulating signalsprovided to the first coil 145 and the second coil 175 may beestablished instead of the out-of-band communication. In theseembodiments, the first transceiver 130 and the second transceiver 160may not be required or may be modified accordingly.

The method 200 also includes establishing one of the first electricaldevice 110 and the second electrical device 115 as the power transmitterand the other of the first electrical device 110 and the secondelectrical device 115 as the power receiver (at block 220). The firstelectronic processor 120 and the second electronic processor 150negotiate over the wireless connection established between the firstelectrical device 110 and the second electrical device 115. The firstelectronic processor 120 and/or the second electronic processor 150determine which one of the first electrical device 110 and the secondelectrical device 115 is to be the power transmitter and the powerreceiver. In some embodiments, the first electronic processor 120 and/orthe second electronic processor 150 determine the power transmitter andthe power receiver based on a user instruction received via a userinterface of the first electrical device 110 and/or the secondelectrical device 115.

The method 200 also includes converting, using a transmitter powerconversion circuit, input power to AC power (at block 230). Followingthe above example, the first power conversion circuit 135 (for example,the transmitter power conversion circuit) converts power received fromthe power input 180 into an AC power. The method 200 further includesproviding, using a transmitter control unit, alternating current to atransmitter coil (at block 240). For example, as described above, thefirst control unit 140 (for example, the transmitter control unit)provides alternating current from the first power conversion circuit 135to the first coil 145.

The method 200 also includes generating, using a transmitter coil, anoscillating magnetic field (at block 250). The alternating currentflowing through the first coil 145 (for example, the transmitter coil)generates an oscillating magnetic field. The method 200 further includesgenerating an alternating current in a receiver coil (at block 260). Theoscillating magnetic field induces an electromotive force that createsthe alternating current in the second coil 175 (for example, thereceiver coil).

The method 200 also includes converting, using a receiver powerconversion circuit, the alternating current to direct current (at block270). The second control unit 170 (for example, a receiver control unit)provides the alternating current generated in the second coil 175 to thesecond power conversion circuit 165 (for example, the receiver powerconversion circuit). The second power conversion circuit 165 convertsthe alternating current to direct current, for example, using arectifier. The method 200 further includes providing, using the receiverpower conversion circuit, the direct current to a load (at block 280).The second power conversion circuit 165 provides the direct current atthe power output 185 to a connected load.

FIG. 3 is a block diagram of one embodiment of a non-contact separablewiring device power transfer system 300. In the example illustrated, thenon-contact separable wiring device power transfer system 300 includes apower transmitter device 310 and a power receiver device 315 in a powertransfer relationship with each other. In the non-contact separablewiring device power transfer system 300 electrical power is transferredfrom the power transmitter device 310 to the power receiver device 315.The power transmitter device 310 includes a transmitter electronicprocessor 320, a transmitter memory 325, a transmitter transceiver 330,a transmitter control unit 335, and a transmitter coil 340. The powerreceiver device 315 includes a receiver electronic processor 345, areceiver memory 350, a receiver transceiver 355, a receiver powerconversion circuit 360, a receiver control unit 365, and a receiver coil370. The power transmitter device 310 and the power receiver device 315may include more or fewer components than those illustrated in FIG. 3and may perform additional functions other than those described herein.

The transmitter electronic processor 320, the transmitter memory 325,the transmitter transceiver 330, the receiver electronic processor 345,the receiver memory 350, and the receiver transceiver 355 areimplemented similar to the first electronic processor 120, the firstmemory 125, and the first transceiver 130 respectively as describedabove.

The transmitter control unit 335 receives power from a power input 375.The transmitter control unit 335 may include a power conversion circuit,for example, if it is necessary, or otherwise desired, to convert powerinput 375 to another form, e.g., different frequency, phase, etc. In oneexample, the power input 375 is a multi-phase AC power input that isconverted to a single-phase AC power to be provided to the transmittercontrol unit 335. In one example, the power input 375 is a directcurrent (DC) grid, digital electricity source, and the like. Thetransmitter control unit 335 is controlled by the transmitter electronicprocessor 320 to provide an alternating current to the transmitter coil340. The alternating current through the transmitter coil 340 creates anoscillating magnetic field around the transmitter coil 340. Theoscillating magnetic field induces an alternating electromotive forcethat creates an alternating current in the receiver coil 370. Thereceiver electronic processor 345 controls the receiver control unit 365to provide the alternating current from the receiver coil 370 to thereceiver power conversion circuit 360. Receiver power conversion circuit360 converts the alternating current in the receiver coil 370 to one ofa DC power and other forms of AC power based on the implementation ofthe non-contact separable wiring device power transfer system 300.

In one example implementation, the receiver power conversion circuit 360converts the AC power received from the receiver coil 370 into a DCpower at a power output 380. For example, although not shown in theexemplary embodiment of FIG. 3 , the receiver power conversion circuit360 may include a rectifier to convert the AC power from the receivercoil 370 to a DC power output to a load. In another exampleimplementation, e.g., the one shown in FIG. 3 , the receiver powerconversion circuit 360 converts the AC power received from the receivercoil 370 into a three-phase AC power at the power output 380. Forexample, the receiver power conversion circuit 360 may include one ormore transformers to convert the single phase AC power from the receivercoil 370 to a three-phase AC power output to a load. In another example,the receiver power conversion circuit 360 may include anelectronic-switch based circuit that alters the input to outputcharacteristics of the AC power.

In accordance with the exemplary embodiment shown, non-contact separablewiring device power transfer system 300 is configured for a powertransfer of between 0.1 to 3.2 kiloWatts. In some embodiments, the powertransmitter device 310 is configured to transfer between 1 to 100kiloWatts of power to the power receiver device 315.

FIG. 4 is a flowchart illustrating one example method 400 for operatingthe non-contact separable wiring device power transfer system 300. Itshould be understood that the order of the steps disclosed in method 400could vary. Additional steps may also be added to the control sequenceand not all of the steps may be required. As illustrated in FIG. 4 , themethod 400 includes establishing communication between the powertransmitter device 310 and the power receiver device 315 (at block 410).For example, a Bluetooth® connection, a Zigbee® connection, or the likemay be established between the power transmitter device 310 and thepower receiver device 315 to facilitate communication between thetransmitter electronic processor 320 and the receiver electronicprocessor 345. The wireless communication between the power transmitterdevice 310 and the power receiver device 315 using Bluetooth® and thelike is referred to as out-of-band communication. In some embodiments,an in-band communication based on modulating signals provided to thetransmitter coil 340 and the receiver coil 370 may be establishedinstead of the out-of-band communication. In these embodiments, thetransmitter transceiver 330 and the receiver transceiver 355 may not berequired or may be modified accordingly.

The method 400 also includes negotiating power transfer requirementsbetween the power transmitter device 310 and the power receiver device315 (at block 420). The transmitter electronic processor 320 and thereceiver electronic processor 345 negotiate over the wireless connectionestablished between the power transmitter device 310 and the powerreceiver device 315. The transmitter electronic processor 320 and thereceiver electronic processor 345 negotiate to determine the powerrequirement, for example, the voltage, frequency, and the like for thenon-contact power transfer. In one embodiment, the receiver electronicprocessor 345 communicates the power requirements of the power receiverdevice 315 to the transmitter electronic processor 320 and thetransmitter electronic processor 320 controls the transmitter controlunit 335 accordingly.

The method 400 also includes providing, using the transmitter controlunit 335, alternating current to the transmitter coil 340 (at block430). For example, as described above, the transmitter control unit 335provides alternating current from the power input 375 to the transmittercoil 340. The method 400 further includes generating, using thetransmitter coil 340, an oscillating magnetic field (at block 440). Thealternating current flowing through the transmitter coil 340 generatesan oscillating magnetic field. The method 400 also includes generatingan alternating current in the receiver coil 370 (at block 450). Theoscillating magnetic field induces an electromotive force that createsthe alternating current in the receiver coil 370.

The method 400 also includes converting, using the receiver powerconversion circuit 360, the alternating current to a desired outputpower (at block 460). The receiver control unit 365 provides thealternating current generated in the receiver coil 370 to the receiverpower conversion circuit 360. The receiver power conversion circuit 360converts the alternating current to a direct current, a three-phasealternating current, or the like based on the requirements of the powerreceiver device 315 as described above. The method 400 further includesproviding, using the receiver power conversion circuit 360, the outputpower to a load (at block 470). The receiver power conversion circuit360 provides the desired output at the power output 380 to a connectedload.

In some embodiments, the non-contact separable wiring device powertransfer system 300 is used for metering and monitoring power draw. Forexample, the power transmitter device 310 includes one or more sensorsto detect a current draw, a temperature and the like. The powertransmitter device 310 uses the current draw sensor to detect and meterpower draw. A power cut-off device may be provided in the powertransmitter device 310 to prevent excess power draw from a powerreceiver device 315. In one example, the power draw is metered such thatthe power transmitter device 310 cuts off power output after theallotted power draw by a power receiver device 315 has been exceeded.

The power transmitter device 310 may also monitor a temperature andother parameters of the non-contact separable wiring device powertransfer system 300. The power transmitter device 310 provides statisticincluding, for example, temperature, power draw, information aboutconnected loads (e.g., when a device exceeds allotted power), health ofthe power transmitter device 310, health of the power receiver device315, and the like to a gateway device or a user device. The gatewaydevice is, for example, a server or other computing device of an entitywhere the non-contact separable wiring device power transfer system 300is installed. The user device is, for example, a smartphone applicationassociated with the non-contact separable wiring device power transfersystem 300. The transmitter transceiver 330 may communicate wirelesslyover a communication network with the gateway device or the user deviceto provide the statistics. In an embodiment where the power transmitterdevice 310 is powered by digital electricity, the power transmitterdevice 310 may further communicate with the digital electricity sourceto control the power flow.

FIG. 5 is a block diagram of one embodiment of a multi-node non-contactseparable wiring device power transfer system 500. In the exampleillustrated, the multi-node non-contact separable wiring device powertransfer system 500 includes a power transmitter device 510 and aplurality of power receiver devices 515. The power transmitter device510 is in in a power transfer relationship with each of the plurality ofpower receiver devices 515. In the multi-node non-contact separablewiring device power transfer system 500 electrical power is transferredfrom the power transmitter device 510 to one or more of the plurality ofpower receiver device 515. The power transmitter device 510 includes atransmitter electronic processor 520, a transmitter memory 525, atransmitter transceiver 530, a transmitter control unit 535, and aplurality of transmitter coils 540. The plurality of the power receiverdevices 515 may be singularly referred to as a power receiver device515. The plurality of power receiver devices 515 includes a first powerreceiver device 515A, a second power receiver device 515B, and so on.The power receiver device 515 includes a receiver electronic processor545, a receiver memory 550, a receiver transceiver 555, a powerconversion circuit 560, a receiver control unit 565, and a receiver coil570. The power transmitter device 510 and the plurality of powerreceiver device 515 may include more or fewer components than thoseillustrated in FIG. 5 and may perform additional functions other thanthose described herein.

The components of the power transmitter device 510 function similarly asthe components of the power transmitter device 310 of FIG. 3 . However,the power transmitter device 510 divides and distributes the input powerto the plurality of transmitter coils 540. The plurality of powerreceiver devices 515 function similar to the power receiver device 315of FIG. 3 .

FIG. 6 is a flowchart illustrating one example method 600 for operatingthe power transmitter device 510. It should be understood that the orderof the steps disclosed in method 600 could vary. Additional steps mayalso be added to the control sequence and not all of the steps may berequired. As illustrated in FIG. 6 , the method 600 includesestablishing communication, using the transmitter electronic processor520, with the plurality of power receiver devices 515 (at block 610). Asdiscussed above, the power transmitter device 510 may establish in-bandor out-of-band communication with each of the plurality of powerreceiver devices 515. The method 600 also includes determining, usingthe transmitter electronic processor 520, a priority and powerrequirements of the plurality of power receiver devices 515 (at block620). The transmitter electronic processor 520 communicates with each ofthe plurality of power receiver devices 515 to negotiate powerrequirements of the plurality of power receiver devices 515. Thetransmitter electronic processor 520 may also determine a priority foreach of the plurality of power receiver devices 515.

The method 600 also includes dividing, using the transmitter controlunit 535, input power between the plurality of transmitter coils 540based on the priority and power requirements of the plurality of powerreceiver devices 515 (at block 630). In some embodiments, thetransmitter control unit 535 may divide the input power equally betweenthe plurality of transmitter coils 540 irrespective of the powerrequirements of the plurality of power receiver devices 515. In someembodiments, transmitter control unit 535 may divide the input powerbetween the plurality of transmitter coils 540 in proportion to thepower requirements of the plurality of power receiver devices 515.

In some embodiments, the power requirements of one or more of theplurality of power receiver devices 515 may change during operation. Thetransmitter electronic processor 520 may continuously communicate withthe plurality of power receiver devices 515 to update the powerrequirements of the plurality of power receiver devices 515. Thetransmitter control unit 535 re-divides the input power between theplurality of transmitter coils 540 based on the updated powerrequirements of the plurality of power receiver devices 515. In someembodiments, the transmitter control unit 535 may disable a subset ofthe plurality of transmitter coils 540 in order to address large powerrequirements of a higher priority power receiver device 515.

Many electrical devices are now used in harsh environments, for example,restaurant kitchens, stadiums, conventions centers, outdoor arenas, golfcourses, and the like. These harsh environments originally used gaspowered devices that are usually loud and inefficient and produceemissions. These gas powered devices are being replaced by wiredelectrical devices that are powered from electrical power inputs, forexample, power grid, DC grid, digital electricity, and the like.However, wired electrical devices pose their own issues when used inharsh environments where daily cleaning or sanitation is performed. Forexample, having bare power outlets and power cords may produce a risk ofshock to persons in the presence of cleaning solutions. Additionally,the power cords may be a tripping hazard for employees and customers.

The non-contact separable wiring device power transfer system 300 isportable and improves user-accessibility. Additionally, the non-contactseparable wiring device power transfer system 300 is provided in sealedand waterproof housings so that the non-contact separable wiring devicepower transfer system 300 can be used in harsh environments.Specifically, the power transmitter device 310 includes a hermeticallysealed housing and may be provided behind walls, in the flooring, in theground, and the like. In some embodiments, the power transmitter device310 may be provided on the walls, on the flooring, on the ground, andthe like. For example, the sealed housing of the power transmitterdevice is partially or completely provided within a surface. Similarly,the power receiver device 315 also includes a hermetically sealedhousing and may form part of an electrical device or an electricalappliance, for example, a fryer, an electric stove, lights, and thelike.

FIGS. 7A-C illustrate an example implementation of the non-contactseparable wiring device power transfer system 300. In the exampleillustrated, the power transmitter device 310 is integrated into avertical surface 710, for example, a wall surface. Referring to FIG. 7B,the power receiver device 315 is provided within and forms part of anelectrical device or appliance 740, for example, a kitchen fryer.Referring to FIG. 7C, the power receiver device 315 is coupled to a theelectrical device or appliance 740, for example, a kitchen fryer using awire. As shown in FIGS. 7B-C, the non-contact separable wiring devicepower transfer system 300 is provided in, for example, a fast foodrestaurant. The non-contact separable wiring device power transfersystem 300 allows for a kitchen appliance to be moved when, for example,the fast food restaurant is switching from a breakfast to a lunch/dinnermenu. Additionally, the non-contact separable wiring device powertransfer system 300 allows for easier and safe cleaning of the kitchenarea as there are no bare power outlets or wires.

FIGS. 8A-C illustrate an example implementation of the non-contactseparable wiring device power transfer system 300. In the exampleillustrated, the power transmitter device 310 is integrated into ahorizontal surface 720, for example, a floor surface, a table surface,the ground (for example, underground), and the like. Referring to FIG.8B, the power receiver device 315 is provided within and forms part ofan electrical device or appliance 740, for example, a floor outlet box.Referring to FIG. 8C, the power receiver device 315 is coupled to theelectrical device or appliance 740, for example, a floor outlet boxusing a wire. As shown in FIGS. 8B-C, the non-contact separable wiringdevice power transfer system 300 is provided in, for example, a shoppingmall, outdoor arena, and the like. The non-contact separable wiringdevice power transfer system 300 allows for the floor outlet box to bemoved when, for example, the floor outlet box is needed at a differentlocation or to be removed when an event is completed. Additionally, thenon-contact separable wiring device power transfer system 300 allows foreasier and safe cleaning of the shopping mall or outdoor arena as thereare no bare power outlets or wires. Since there are no bare outletsprovided during cleaning or switching over, any cleaning solution orliquid used during cleaning does not enter the power transmitter device310 or the power receiver device 315. This allows for the non-contactseparable wiring device power transfer system 300 to be used in harshenvironments.

FIG. 9 illustrates an example configuration of the non-contact separablewiring device power transfer system 300 of FIGS. 7C and 8C. As shown inFIG. 9 , the receiver coil 370 is provided beside the transmitter coil340. The receiver control unit 365 provides the power from the receivercoil 370 to the wiring device 750 to be provided to the load of thepower receiver device 315.

FIGS. 10A-B illustrate an example coupling 1000 between the powertransmitter device 310 and the power receiver device 315. As shown inFIG. 10A, the power transmitter device 310 device includes a flat baseportion 1010 (for example, a transmitter portion) and a raised ledgeportion 1020 around the flat base portion 1010 with an opening 1030 onan inner side of the raised ledge portion 1020. The raised ledge portion1020 may be of any shape, for example, a square, a rectangle, a circle,and the like and forms a socket with the opening 1030. The transmittercoil 340 is provided in the flat base portion 1010. The power receiverdevice 315 includes a flat portion 1040 and a raised portion 1050 (forexample, a receiver portion). The raised portion 1050 is of a similarshape as the raised ledge portion 1020 and forms a plug that is receivedin the socket formed by the raised ledge portion 1020 and the opening1030. The receiver coil 370 is provided in the raised portion 1050.

In some embodiments, as shown in FIG. 10B, a first magnet 1060 and asecond magnet 1070 may be used to couple the power transmitter device310 and the power receiver device 315. The first magnet 1060 is providedin the flat base portion 1010 of the power transmitter device 310 belowthe opening 1030. The first magnet 1060 is provided, for example, in thecenter of the transmitter coil 340 to avoid interference with themagnetic field generated by the transmitter coil 340. The second magnet1070 is provided in the raised portion 1050 of the power receiver device315. The second magnet 1070 is similarly provided, for example, in thecenter of the receiver coil 370 to avoid interference with the magneticfield generated by the transmitter coil 340. One advantage of providingthe first magnet 1060 and the second magnet 1070 prevents accidentalde-coupling of the power transmitter device 310 and the power receiverdevice 315, but still prevents any damage to the components when thepower transmitter device 310 and the power receiver device 315 arede-coupled due to inadvertent pulling of the devices.

The power transmitter device 310 and the power receiver device 315 maybe coupled using the plug and socket configuration shown in FIGS. 10Aand 10B. In some embodiments, other coupling configurations may be usedto couple the power transmitter device 310 and the power receiver device315. In the above example, the flat base portion 1010 (that is, thetransmitter portion) and the raised portion 1050 (that is, the receiverportion) are aligned to axially align the transmitter coil 340 and thereceiver coil 370 (see FIG. 3 ) without an air gap between the flat baseportion 1010 and the raised portion 1050.

In some embodiments, the coupling 1000 between the power transmitterdevice 310 and the power receiver device 315 may be implemented withoutthe plug and socket configuration illustrated in FIGS. 10A and 10B. Forexample, as illustrated in FIG. 11 , the power transmitter device 310device includes a flat base portion 1110 (for example, a transmitterportion). The transmitter coil 340 is provided in the flat base portion1110. The power receiver device 315 includes a flat portion 1120 (forexample, a receiver portion). The receiver coil 370 is provided in theflat portion 1120. When the power transmitter device 310 and the powerreceiver device 315 are coupled, the flat base portion 1110 and the flatportion 1120 are aligned to axially align the transmitter coil 340 andthe receiver coil 370 without an air gap between the flat base portion1110 and the flat portion 1120.

In some embodiments, a first magnet 1060 and a second magnet 1070 (asshown in FIG. 10B) may similarly be used to couple the power transmitterdevice 310 and the power receiver device 315. The first magnet 1060 isprovided in the flat base portion 1110 of the power transmitter device310, for example, in the center of the transmitter coil 340 to avoidinterference with the magnetic field generated by the transmitter coil340. The second magnet 1070 is provided in the flat portion 1120 of thepower receiver device 315, for example, in the center of the receivercoil 370 to avoid interference with the magnetic field generated by thetransmitter coil 340.

Thus, the application provides, among other things, inductive powertransfer systems.

We claim:
 1. A non-contact power transmitter device comprising: astructure configured to form a floor; a sealed housing integrated intothe structure and including a flat base portion; a transmitter coilprovided within the flat base portion and configured to inductivelytransfer power to a power receiver device, wherein the flat base portionis configured to be aligned with a flat portion of the power receiverdevice, wherein a receiver coil of the power receiver device is providedin the flat portion, wherein the flat base portion and the flat portionare aligned to axially align the transmitter coil and the receiver coilwithout an air gap between the flat base portion and the flat portion; atransmitter control unit coupled to the transmitter coil; a transceiverconfigured to communicate with the power receiver device; and anelectronic processor coupled to the transmitter control unit and thetransceiver and configured to, establish, using the transceiver,communication with the power receiver device, negotiate power transferrequirements between the non-contact power transmitter device and thepower receiver device, and control the transmitter control unit totransfer power to the power receiver device a raised ledge portionaround the flat base portion having an opening on an inner side of theraised ledge portion, wherein the raised ledge portion and the flat baseportion are configured to receive a raised portion of the power receiverdevice, and wherein the receiver coil of the power receiver device isprovided in the raised portion.
 2. The non-contact power transmitterdevice of claim 1, wherein the transmitter control unit is configured toprovide a first alternating current to the transmitter coil; andgenerate, using the transmitter coil, an oscillating magnetic field,wherein the oscillating magnetic field generates a second alternatingcurrent in the receiver coil of the power receiver device.
 3. Thenon-contact power transmitter device of claim 1, further comprising: afirst magnet provided in the flat base portion, the first magnetprovided in a center of the transmitter coil; and a second magnetprovided in the raised portion, the second magnet provided in a centerof the receiver coil, wherein when the raised portion is received in theopening formed by the raised ledge portion, the first magnet is coupledto the second magnet due to a magnetic force between the first magnetand the second magnet.
 4. The non-contact power transmitter device ofclaim 1, further comprising: a second transmitter coil within the sealedhousing configured to inductively transfer power to a second powerreceiver device; wherein the electronic processor is further configuredto: establish, using the transceiver, communication with the powerreceiver device and the second power receiver device, determine priorityand power requirements of the power receiver device and the second powerreceiver device based on the communication with the power receiverdevice and the second power receiver device, and control the transmittercontrol unit to divide power between the transmitter coil and the secondtransmitter coil based on the priority and power requirements.
 5. Thenon-contact power transmitter device of claim 1, wherein establishingcommunication with the power receiver device includes establishing anout-of-band communication, wherein the power transfer requirements arenegotiated using the out-of-band communication.
 6. The non-contact powertransmitter device of claim 1, wherein the electronic processor isfurther configured to: transmit, using the transceiver, one or moreselected from the group consisting of temperature, power draw,information about connected loads, and health of the non-contact powertransmitter device to a gateway device.
 7. The non-contact powertransmitter device of claim 1, wherein the electronic processor isfurther configured to: transmit, using the transceiver, one or moreselected from the group consisting of temperature, power draw,information about connected loads, and health of the non-contact powertransmitter device to a user device.
 8. The non-contact powertransmitter device of claim 1, wherein the electronic processor isfurther configured to determine, using a current draw sensor, a currentdraw of the power receiver device; and cut-off, using a power cut-offdevice, power output to the power receiver device when the current drawexceeds an allotted power draw for the power receiver device.
 9. Anon-contact power transfer system comprising: a power transmitter deviceincluding a structure configured to form a floor, a sealed housingintegrated into the structure and including a flat base portion, araised ledge portion around the flat base portion having an opening onan inner side of the raised ledge portion, a transmitter coil providedin the flat base portion, a transmitter control unit coupled to thetransmitter coil, a transmitter transceiver, and a transmitterelectronic processor coupled to the transmitter control unit and thetransmitter transceiver; and an electrical appliance including a powerreceiver device configured to be coupled in a power transferrelationship with the power transmitter device, the power receiverdevice including a second sealed housing provided at least partiallywithin the electrical appliance and including a flat portion, a receivercoil within the flat portion, wherein the transmitter coil is configuredto inductively transfer power to the receiver coil, wherein the flatbase portion and the flat portion are aligned to axially align thetransmitter coil and the receiver coil without an air gap between theflat base portion and the flat portion, wherein the flat portion isprovided on a projecting portion of the electrical appliance, whereinthe raised ledge portion and the flat base portion are configured toreceive the projecting portion of the electrical appliance, a powerconversion unit coupled to the receiver coil, a receiver transceiver,and a receiver electronic processor coupled to the power conversion unitand the receiver transceiver, wherein the transmitter electronicprocessor is configured to establish, using the transmitter transceiver,communication with the power receiver device, negotiate power transferrequirements between the power transmitter device and the power receiverdevice, and control the transmitter control unit to transfer power tothe power receiver device.
 10. The non-contact power transfer system ofclaim 9, wherein the transmitter control unit is configured to provide afirst alternating current to the transmitter coil, and generate, usingthe transmitter coil, an oscillating magnetic field, wherein theoscillating magnetic field generates a second alternating current in thereceiver coil.
 11. The non-contact power transfer system of claim 10,wherein the power conversion unit is configured to convert the secondalternating current to a direct current; and provide the direct currentto a load of the power receiver device.
 12. The non-contact powertransfer system of claim 10, wherein the power conversion unit isconfigured to convert the second alternating current to output power;and provide the output power to a load of the power receiver device. 13.The non-contact power transfer system of claim 12, wherein the secondalternating current is a single phase alternating current and whereinconverting the second alternating current to the output power includingconverting the single phase alternating current to three-phasealternating current.
 14. The non-contact power transfer system of claim9, further comprising: a first magnet provided in the flat base portion,the first magnet provided in a center of the transmitter coil; and asecond magnet provided in the projecting portion, the second magnetprovided in a center of the receiver coil, wherein when the projectingportion is received in the opening formed by the raised ledge portion,the first magnet is coupled to the second magnet due to a magnetic forcebetween the first magnet and the second magnet.
 15. The non-contactpower transfer system of claim 9, wherein the transmitter electronicprocessor is further configured to: transmit, using the transmittertransceiver, one or more selected from the group consisting oftemperature, power draw, information about connected loads, and healthof the power transmitter device to a user device.
 16. The non-contactpower transfer system of claim 9, wherein the transmitter electronicprocessor is further configured to determine, using a current drawsensor, a current draw of the electrical appliance; and cut-off, using apower cut-off device, power output to the electrical appliance when thecurrent draw exceeds an allotted power draw for the electricalappliance.